Layout optimization of a dual-robot system for mirror milling of thin-walled parts

Layout optimization is crucial in the development of a dual-robot system, as it significantly affects the cooperative working efficiency and workspace utilization. This paper conducts layout optimization of a dual-robot system for mirror milling including a serial robot and a hybrid robot. A comprehensive layout optimization method that considers multiple indexes is proposed. Four quantification indexes are considered to optimize layout parameters including overlap workspace, regional manipulability, regional bearing capacity, and maximum regular workspace. The milling robot and the supporting robot are modeled geometrically, and the overlap workspace of the two robots is obtained by using a kinematics model. The manipulability and bearing capacity of the supporting robot are analyzed, and the area with low performance is eliminated from the workspace. For solving the maximum regular workspace, a nonlinear programming algorithm is proposed, thereby avoiding the complex mathematical derivation. After four quantification indexes are quantified, a comprehensive quantification index is calculated using a principal component analysis, which is able to analyze the correlation between the multiple indexes. A comprehensive quantification model is established to solve the optimal layout parameters. The proposed layout optimization method displays superior performance in the milling experiment.